Resin application system and method

ABSTRACT

Non-woven matrices and, more particularly, cotton shoddy and/or natural fiber matrices, and systems and methods for producing the matrices are described herein.

CROSS-REFERENCE TO THE RELATED APPLICATION

The present application claims the benefit of the provisional patentapplication Ser. No. 61/739,376, filed Dec. 19, 2012, which isincorporated herein by reference.

BACKGROUND

The subject matter disclosed herein relates generally to non-wovenmatrices and, more particularly, to cotton shoddy and/or natural fibermatrices and systems and methods for producing cotton shoddy matrices.

Commercially available technology exists today for the purpose ofapplying liquids to a non-woven matrix, such as a matrix constructedfrom natural fiber and/or cotton shoddy. One technology includes dippinga continuous feed of a non-woven matrix into a tank of emulsion resin,then squeezing the resin-saturated matrix to remove excess content,while a second technology includes converting emulsion resin into adense foam using a foam generating system, and injecting the foam intothe matrix under pressure using a specially designed application headmade for this purpose. While both of these technologies may work to somedegree for certain natural fiber non-woven matrices, neither is wellsuited to resin-saturate cotton shoddy.

Several disadvantages exist with conventional foam injection processes.Foam injection requires a continuous feed of a non-woven matrix. Afterfoam is injected into the non-woven matrix, the non-woven matrix is cutto appropriate size requirements and dried prior to final processing.Further, foam injection requires a wider matrix than an actual foamapplication area. This excess material provides an edge seal to preventfoam from escaping from an edge area of the continuously moving matrixduring foam impregnation. This process does not allow the recycling ofthe excess of material after cutting to size before resin impregnation.In addition, only one side of the continuously feed matrix can beinjected with foam having a certain desired uniformity of application.This, therefore, requires two passes of the non-woven matrix through thefoam injection applicator in order to completely resonate the non-wovenmatrix. Foam injection also tends to be expensive. Capital costs arehigher, process application of resonating matrix is slower, andtherefore this is an undesirable means of applying a liquid resin intonon-woven matrix.

Several disadvantages also exist with conventional dip and squeezeprocesses. The conventional dip and squeeze process is often undesirablebecause of problems associated with accuracy of application. However,dip and squeeze may have a better throughput capability thanconventional foam injection processes. Similar to the foam injectionprocess, conventional dip and squeeze technology requires the product tobe run using a continuous feed of non-woven matrix. It does not allowthe recycling of the excess material after cutting to size before resinimpregnation.

It is desirable to develop an application system that utilizes thesimplicity of a dip and squeeze process or applying the resin on a scrimand then laminating the scrim on a matrix made of thermoplastic andcotton shoddy and/or natural fibers, and achieves the accuracy resultsof a foam injection process, while doing so with a feed of precut matrixblanks as opposed to roll goods required for existing technology.

SUMMARY

In one aspect, a process system incorporates a modified dip and squeezeprocess system combined with a modified injection system that pumpsnon-foam resin directly into a non-woven matrix while the non-wovenmatrix remains substantially submerged in a resin contained within aresin tank.

In another aspect, a method for producing cotton shoddy and/or naturalfiber matrices includes a modified dip and squeeze process combined witha modified injection process that pumps non-foam resin directly into thenon-woven matrix while the non-woven matrix remains substantiallysubmerged in a resin contained within a resin tank.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an exemplary device for impregnating amatrix blank with a resin;

FIG. 2A is a schematic view of the device shown in FIG. 1, with theframing and support structure removed for clarity;

FIG. 2B is a schematic view of an exemplary device for impregnating amatrix blank with a resin including a plurality of compression squeezerolls;

FIG. 3 is a schematic view of an exemplary application line includingthe device shown in FIGS. 1 and 2A, coupled to a microwave forced airdrying oven; and

FIG. 4 is a schematic view of an exemplary application line includingthe device shown in FIGS. 1 and 2A, coupled to a hot air drying oven.

DETAILED DESCRIPTION

The embodiments described herein are directed to a non-woven matrix,such as a non-phenol formaldehyde cotton shoddy matrix, for example, anda process system for the application of a suitable emulsify resin, suchas an Acrodur™ resin available from BASF Aktiengesellschaft Corp.,Ludwigshafen am Rhein, Germany, for example, that substantiallycompletely saturates the cotton shoddy matrix through a thickness of thecotton shoddy matrix. In certain embodiments, the process system isscalable to meet any application requirement. In addition and for meansof practicality, in certain embodiments the system design intentincludes the ability to resonate individual cut sheet sizes without theneed for a continuous feed of matrix. This will facilitate recycling theexcess of material after cutting to size before resin impregnation.

In the following description, the embodiments are described in relationto a cotton shoddy matrix. This is by way of example only, it beingunderstood that the embodiments may be implemented for use with suitablenatural fiber non-woven matrices.

In one embodiment, the process system incorporates a modified dip andsqueeze process system combined with a modified injection system thatpumps non-foam resin directly into the non-woven matrix while thenon-woven matrix remains substantially submerged in a resin containedwithin a resin tank, as described in greater detail below with referenceto FIGS. 1-4. Unlike conventional dip and squeeze systems, the processsystem described herein allows for the use of precut matrix blanks priorto resonating. In a particular embodiment, the process system includestwo open weave, glass fiber belts coated with a Teflon™ coating to carryeach matrix blank through the resin application process to significantlyreduce the strain on the non-woven matrix blank during saturation, andfurther reduce or eliminate any tensile pull on the matrix blank duringthe process, an undesirable affect caused by conventional systems. Thissystem allows to dip and squeeze material in both directions (machinedirection and cross-machine direction) which is not reasonably possiblein conventional foam injection and continuous dip and squeeze systems.

Resonating cotton shoddy with a liquid resin product is virtuallyimpossible to achieve using existing dip and squeeze technology. Acotton shoddy non-woven matrix does not have sufficient tensile strengthto carry the matrix through a conventional dip and squeeze systemwithout tearing under the nominal tensile pulls that are typicallyexerted on a product during a resin application and post-matrix drying.Additionally, the wet pick up rate (the rate of added weight of resinand water to fully impregnate the cotton shoddy matrix) adds more than110% additional weight to a pre-resonated matrix weight. The additionalweight, in addition to the weak strengths of short fiber cotton shoddy,renders existing technologies impractical to adopt for this purpose.

Referring to FIGS. 1-4, an exemplary process system 10 includes a resinapplication station 12, a drying station 14 and a palletizing station 16operatively coupled in series. Referring further to FIGS. 1, 2A and 2B,resin application station 12 includes a tank, such as a stainless steeltank 20 configured to contain a suitable amount of an aqueous solutionof a resin material and water. In a particular embodiment, the aqueoussolution comprises an Acrodur™ resin and water. A first or lowercarrying belt 22 is operatively coupled to and supported by a frame 24.In one embodiment, lower carrying belt 22 is a fiberglass-reinforced,Teflon™ coated open webbing belt, although other belts can be used aslower carrying belt 22. As shown in FIG. 1, frame 24 is a stainlesssteel construction frame configured to support the associated componentsof resin application station 12, for example, associated belts,bearings, and drives. Resin application station 12 also includes one ormore belt rolls 26 and a fixed compression roll 28 to further supportlower carrying belt 22, and a bottom belt drive unit 30 configured todrive lower carrying belt 22 about belt rolls 26. In one embodiment,belt drive unit 30 includes a PLC-controlled, AC inverter drive withgear reductions for lower carrying belt 32, as well as for a cooperatingupper carrying belt 32.

In one embodiment, upper carrying belt 32 is a fiberglass-reinforced,Teflon™ coated open webbing belt, as described above with reference tolower carrying belt 22, although other belts can be used as uppercarrying belt 32. In other embodiments, upper carrying belt 32 may bethe same as or different than lower carrying belt 22. Upper carryingbelt 32 is operatively coupled to and supported by stainless steel frame24, one or more belt rolls 36, and an adjustable compression roll 38. Abelt drive unit 40 is configured to drive upper carrying belt 32 aboutbelt rolls 36. In one embodiment, belt drive unit 40 includes aPLC-controlled, AC inverter drive with gear reductions for uppercarrying belt 32. Alternatively, belt drive unit 30 may include aPLC-controlled, AC inverter drive with gear reductions for uppercarrying belt 32, as well as for lower carrying belt 22.

Referring again to FIG. 1, a level 42 of the aqueous solution ismaintained in tank 20 to sufficiently submerge a matrix blank 43,securely positioned between lower carrying belt 22 and upper carryingbelt 32, in the aqueous solution. In one embodiment, level 42 ismaintained by using a sonic level control device or other suitable levelcontrol device, which adds a desired amount of pre-mixed aqueoussolution to tank 20 as required.

In one embodiment, electrically-driven screw jacks 44, shown in FIG. 1,are configured to move or urge adjustable compression roll 38 withrespect to fixed compression roll 28. In a particular embodiment, screwjacks 44 are activated to move adjustable compression roll 38 to apredetermined point with respect to an outer surface of fixedcompression roll 28 to define a gap 46, shown in FIG. 2A, through whichlower carrying belt 22 and upper carrying belt 32 carry matrix blank 43saturated with resin. A gap clearance is adjustable through theactivation of screw jacks 44 to set a compression force applied to thesaturated matrix blank 43 as matrix blank 43 is carried by lowercarrying belt 22 and upper carrying belt 32 through gap 46. As thesaturated matrix blank 43 moves continuously through gap 46 under adesired compression force applied by the cooperating adjustablecompression roll 38 and fixed compression roll 28, excess resin andwater is flushed from the saturated matrix blank 43 providing animpregnated matrix blank 43 having an amount of resin/water solutionequal to a total wet pickup required to achieve a desired percentage ofresin dry solids add-on. As shown in FIG. 2B, in one embodiment, resinapplication system 12 includes a plurality of adjustable compressionroll sets, such as a series of three adjustable compression roll sets38A, 38B, and 38C, to facilitate removing excess resin and water fromthe saturated matrix blank 43.

Referring to FIG. 3, the impregnated matrix blank 43 is transferred fromresin application station 12 to drying station 14 by a transfer belt 50.In this embodiment, drying station 14 includes a microwave drying oven60 having an air suction fan 62 configured to remove water vapor asmeans to accelerate drying time. Drying oven size depends on dimensions,such as a width, of matrix blanks 43 being dried, as well as a linearflow speed of matrix blanks 43 through drying oven 60. In a particularembodiment, drying oven 60 is a 75 Kw magnetron microwave drying ovencapable of drying resonated matrix blanks 43 having a width of 1.5meters traveling through drying oven 60 at linear flow speed of 5 metersper minute. Microwave drying oven 60, as described herein, provides foran overall size reduction in the line foot print of process system 10and a reduction in energy cost to remove excess water, for example, whencompared with conventional drying stations. Once the impregnated matrixblank 43 is dried, the impregnated matrix blank 43 is transferred froman outlet of drying oven 60 to an automatic stacking device 70 ofpalletizing station 16 by a dry matrix blank conveyor 72 to form a stackof dry matrix blanks 43.

Alternatively, referring to FIG. 4, the impregnated matrix blank 43 istransferred from resin application station 12 to drying station 14 by atransfer belt 50. In this embodiment, drying station 14 includes a hotair drying oven 80. Like microwave drying oven 60 described above, hotair drying oven size depends on dimensions, such as a width, of matrixblanks 43 being dried, as well as a linear flow speed of matrix blanks43 through drying oven 60. Once the impregnated matrix blank 43 isdried, the impregnated matrix blank 43 is transferred from an outlet ofhot air drying oven 80 to an automatic stacking device 70 of palletizingstation 16 by a dry matrix blank conveyor 72 to form a stack of drymatrix blanks 43.

Process system 10 as described with reference to drying station 14 shownin FIGS. 3 and 4 can be utilized with either pre-cut matrix blanks 43 ora matrix roll 82 of desired material, as shown in FIG. 4. With processsystem 10 operating with matrix roll 82 to supply a continuous feed ofmaterial, a guillotine cross-cutter 84 cuts matrix blanks 43 from thecontinuously fed matrix prior to palletizing, for example, as thecontinuous feed of matrix material exits drying oven 80 onto conveyor72, as shown in FIG. 4.

Referring again to FIGS. 1-4, a method for forming impregnated matrixblanks 43 with process system 10 as described herein includes, in oneembodiment, placing a precut matrix blank 43 of cotton shoddy, oranother suitable fibrous non-woven matrix that will absorb an aqueousresin solution, on a top surface of lower carrying belt 22 coated with asuitable coating, such as a Teflon™ coating. Lower carrying belt 22moves at a speed equal to a speed at which upper cooperating carryingbelt 32 moves. In this embodiment, upper carrying belt 32 is also coatedwith a suitable coating, such as a Teflon™ coating.

Lower carrying belt 22 and upper carrying belt 32 meet to secure or trapthe precut matrix blank 43 between lower carrying belt 22 and uppercarrying belt 32 prior to or as matrix blank 43 enters tank 20containing a liquid resin, such as an aqueous solution of a resin andwater. As lower carrying belt 22 and upper carrying belt 32 move throughtank 20, matrix blank 43 secured between opposing and cooperating lowercarrying belt 22 and upper carrying belt 32 is submerged into theaqueous solution contained within tank 20 at a suitable speed to ensurethat matrix blank 43 is submerged in the aqueous solution for asufficient exposure time so that full saturation of the resin throughoutmatrix blank 43 is achieved. For highly absorbent and dense products,such as cotton shoddy, lower carrying belt 22 and upper carrying belt 32slide between two stainless steel spring loaded plates that cover a fullwidth of the belts and at least 24 inches of a running length of thebelts at any time. One or more nozzles are positioned in a middleportion of each plate in a machine direction, and run across the widthof the each plate. Resin is pumped through the one or more nozzles at apredetermined velocity to force resin into a center of matrix blank 43while matrix blank 43 moves in the machine direction. An added length ofthe plates ensures that pressure is focused in a desired treatment area.Pre-load spring pressure is sufficient to keep the nozzles and pressureplates compressed to each belt, thereby forming a seal to prevent resinblow by. Resin is forced under pressure into matrix blank 43 tofacilitate accelerating absorption of the resin to a center core ofmatrix blank 43. Other matrices can be resonated similarly to acceleratethe resonating speed, but this is the only process which ensures cottonshoddy is fully resonated throughout a Z dimension.

At the end of the submersion process, lower carrying belt 22 and uppercarrying belt 32 carrying the resin impregnated non-woven matrix blank43 tum 90 degrees upwards ascending above tank 20 and entering a squeezeprocess to remove excess liquid resin to achieve the desired applicationrate. Using cooperating fixed compression roll 28 and adjustablecompression roll 38, with lower carrying belt 22 and upper carrying belt32 securing matrix blank 43 therebetween, matrix blank 43 moves into andthrough the squeeze rolls. In one embodiment, three compression rollsets are used, one above the other, to facilitate extracting excessresin from the resonated matrix blank. Each of the three verticalcompression rolls, as shown in FIG. 2B, is set at a particular gap toprovide less strain on matrix blank 43, and at the same time applyingthree different rates of pressure on the wetted matrix blank 43 tooptimize solution extraction. (FIG. 1 shows only one set of suchcompression rolls). This squeeze action allows excess resin to flush outof matrix blank 43, flowing equally on opposing sides of the incomingpre-squeezed matrix blank 43 to maintain consistent and uniform liquidexposure equally to opposing sides of matrix blank 43. Exiting squeezerolls, upper carrying belt 32 separates from matrix blank 43 to allowlower carrying belt 22 to deliver matrix blank 43 into a drying oven fordownstream final processing.

EXAMPLES

Example of formulation for application of liquid resin is as follows.

-   -   Resonated cotton shoddy matrix at desired dry weight=1000 gsm.    -   Based weight of composite matrix pre-resonating=770 gsm at 0%        moisture. Active resin required to meet resonated gram weight of        matrix=230 gsm. Acrodur™ resin as supplied by BASF=50% water,        50% active dry solids resin. Required active dry solids solution        to apply resin to cotton shoddy=25%.    -   True wet pick required to apply 230 gsm dry solids        resin=(100/25)=3×230=690 gsm or 89%.

Wet pick up for cotton shoddy to fully wet out matrix blank duringsolution application is greater than 125% or 1250 gsm of aqueoussolution, pick up during dipping matrix in solution or 55%′ greaterdilution in solution mix in order to apply 230 gsm dry solids resin.Therefore the aqueous solution mix needs to be further diluted to(100/18)=5.55×230=1276 gsm.

After resin impregnation, the impregnated matrix blank 43 is dried ofexcess water prior to use. Because the rate of water evaporation is veryhigh compared to the final matrix blank weight (up to 70%), conventionaltechnology using air impingement driers to perform this task requiresovens lengths often exceeding 50 feet and normally greater than 100 feetin length to run at any appreciable speed. This large foot print takesup valuable floor space and, as a means of energy utilization fordrying, is one of the least efficient means to control drying costs.Based on test results, adopting microwave technology in the processingline reduces operating costs and reduces floor space requirements.Microwave oven technology works on the principal of exciting watermolecules through energy waves causing the water molecules to vibraterapidly. Further, microwave technology works on the mass inside out, amore desirable drying method than conventional air impingement ovensthat work through transpiration or wicking water from the inside to thedrier outside. Because final moisture content is critical to thermalprocessing (Acrodur™ resin requires moisture to be present in asufficient quantity to cross-link resin), microwave heating and theability to precisely control the amount of applied energy allows theprocess system to deliver matrix blank 43 having a desired pre-setmoisture content exiting the drying oven without overheating matrixblank 43. Also, due to the intense focused energy microwave technologyoffers, the footprint required for oven drying is reduced by 75% overconventional hot air impingement-type drying. Therefore, in contrast toa conventional air oven that must be about 100 feet long to dry matrixblanks, a microwave drying oven, such as described herein, may be lessthan 25 feet in length. With the use of focused energy, the amount ofenergy required to dry the same material in the same time cycle is alsogreatly reduced.

In certain embodiments, cotton shoddy was formulated to include, withoutlimitation, the following: cotton shoddy comprising cotton shoddyranging from 10% to 90% of dry composite matrix weight, and hi-componentpolyester fiber ranging from 10% to 90% of composite matrix weight, andnatural fiber comprising one or more of the following: jute, tossa,hemp, cori, sisal, curaua, kenaf and other similar fibers ranging from5% to 90% of composite matrix weight, and polyester fiber ranging from10% to 90% of matrix weight.

An exemplary Composite Matrix Weight 770 gsm, comprises the following:

10% hi-component polyester=(770×0.10)=77 grams.  1.

35% natural fiber of any fiber type above=(770×0.35)=269.5 grams.  2

55% cotton shoddy=(770×0.55)=432.5 grams.  3

Another exemplary Composite Matrix has the same weight as follows:

10% bi-component polyester=(770×0.10)=77 grams.  1

90% cotton shoddy=(770×0.90)=693 grams.  2

Yet another exemplary Composite Matrix has the same weight as follows:

10% hi-component polyester=(770×0.10)=77 grams.  1

35% polyester fiber of any fiber type above=(770×0.35)=269.5 grams.  2

55% cotton shoddy=(770×0.55)=432.5 grams.  3

Yet another exemplary Composite Matrix has the same weight as follows:

10% bi-component polyester=(770×0.10)=77 grams.  1

20% polyester fiber of any fiber type above=(770×0.20)=154 grams.  2

45% cotton shoddy=(770×0.45)=346.5 grams.  3

25% natural fiber of any fiber type above=(770×0.25)=192.5 grams.  4

The combination of fiber types used can be in any percent alwaysrequiring two or more of the above fiber types. The percentage andcombination of blends is dependent on the application requirements.

This combination of systems provides a unique opportunity to applyliquid resins to a fibrous matrix, such as a cotton shoddy matrix, thatis sensitive to line process strain and resistant to absorption due todensity. The system viewed in whole, may include one or more of thefollowing in various embodiments.

-   -   1. Resonating matrix blanks of non-woven matrix, which can        include matrix made with one or more of the following materials:        cotton shoddy, natural bast fiber including, but not limited to,        jute, kenaf, curaua, hemp, and other similar cellulous fibers.    -   2. Using twin belts to carrying matrix blanks into a resin tank.    -   3. Using twin belts to limit any strain associated with a dip        and squeeze or direct injection application of any liquid        including resins, adhesives or other such products used as a        binder in matrix.    -   4. Twin plate injection system spring load to apply        predetermined load during direct liquid injection.    -   5. Flow design of system, including upper and lower belts, belt        types and direction of flow.    -   6. Direct pump resin system.    -   7. Parallel resin flow back under squeeze rolls to keep resin        contact equally on both sides.

Additional Data is attached as Appendix A, noting the following:

-   -   1. Sample A, B, C, D, E & L are made with 90% cotton Shoddy and        10% Bico    -   2. Sample F, G and H are made with 20% Hemp+25% Regenerated        Polyester+10% Bico+45% Cotton Shoddy    -   3. Sample I & J are made with 50% PP+40% shoddy+10% Bico    -   4. All the samples with Jute (K samples) are from old runs and        they are all made with 90% Jute (coffee bag)+10% Shoddy.

The described system and methods are not limited to the specificembodiments described herein. In addition, components of each systemand/or steps of each method may be practiced independent and separatefrom other components and method steps, respectively, described herein.Each component and method also can be used in combination with othersystems and methods.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal language of the claims.

APPENDIX A Sample 1*& 2* cut to size 20″ × 65¼″ 1* 1014.1 0.0894 923.4311.00% 60 3680 2585.92 2.55 284.45 1207.88 30.80% 23.55% 1413 1329 2*1053.4 0.0894 959.24 11.00% 60 3550 2496.59 2.37 274.62 1233.86 28.63%22.26% 1444 1357 Sample D10 cut to size 20″ × 65½″ D10* 1043 841.80.0894 766.56  7.00% 60 3150 2308.18 2.7419 161.57 928.13 21.08% 17.41%1086 1021 Sample E10 cut to size 20″ × 65-½″ E10* 946 743.4 0.0894676.91 11.00% 60 3000 2256.63 3.0357 248.23 925.14 36.67% 26.83% 10821018 Sample L cut to size 20″ × 65½″ Dry to Dry to 17% 10% Dry to 5% L10.0 1038.6 0.0894 945.73 11.00% 60 3500 2461.42 2.37 270.76 1216.4828.63% 22.26% 1423 1338 1277 L2 1170.2 0.0894 1065.60 11.00% 60 38502679.79 2.29 294.78 1360.37 27.66% 21.67% 1592 1496 1428 L3 983.1 0.0894895.25 11.00% 60 3500 2516.85 2.56 276.85 1172.11 30.92% 23.62% 13711289 1231 L4 1014.5 0.0894 923.80 11.00% 60 3500 2485.51 2.45 273.411197.20 29.60% 22.84% 1401 1317 1257 L5 1116.1 0.0894 1016.29 11.00% 603750 2633.93 2.36 289.73 1306.03 28.51% 22.18% 1528 1437 1371 L6 1038.60.0894 945.73 11.00% 60 3500 2461.42 2.37 270.76 1216.48 28.63% 22.26%1423 1338 1277 Dry to Dry to Weight after 17% 10% Drying Sample L6 cutto size 12″ × 12″ L6 1 0.0 114.2 0.0894 104.03 11.00% 60 385 270.76 2.3729.78 133.81 28.63% 22.26% 157 147 159 2 103.9 0.0894 94.57 11.00% 60350 246.14 2.37 27.08 121.65 28.63% 22.26% 142 134 144 3 114.2 0.0894104.03 11.00% 60 385 270.76 2.37 29.78 133.81 28.63% 22.26% 157 147 1514 101.5 0.0894 92.41 11.00% 60 342 240.52 2.37 26.46 118.87 28.63%22.26% 139 131 142 5 108.9 0.0894 99.17 11.00% 60 367 258.10 2.37 28.39127.56 28.63% 22.26% 149 140 148 Sample L5 cut to size 12″ × 12″ L5 10.0 109.5 0.0894 99.73 11.00% 60 368 258.48 2.36 28.43 128.16 28.51%22.18% 150 141 150 2 116.7 0.0894 106.24 11.00% 60 392 275.33 2.36 30.29136.52 28.51% 22.18% 160 150 156 3 112.5 0.0894 102.44 11.00% 60 378265.50 2.36 29.21 131.65 28.51% 22.18% 154 145 148 4 127.4 0.0894 115.9911.00% 60 428 300.62 2.36 33.07 149.06 28.51% 22.18% 174 164 166 5 131.80.0894 120.06 11.00% 60 443 311.15 2.36 34.23 154.29 28.51% 22.18% 181170 169 Sample L4 cut to size 12″ × 12″ L4 1 0.0 84.1 0.0894 76.5411.00% 60 290 205.94 2.45 22.65 99.20 29.60% 22.84% 116 109 125 2 89.00.0894 81.03 11.00% 60 307 218.01 2.45 23.98 105.01 29.60% 22.84% 123116 126 3 100.6 0.0894 91.59 11.00% 60 347 246.42 2.45 27.11 118.6929.60% 22.84% 139 131 137 4 95.4 0.0894 86.84 11.00% 60 329 233.64 2.4525.70 112.54 29.60% 22.84% 132 124 135 5 113.0 0.0894 102.94 11.00% 60390 276.96 2.45 30.47 133.40 29.60% 22.84% 156 147 157 Sample L3 cut tosize 12″× 12″ L3 1 0.0 91.0 0.0894 82.87 11.00% 60 324 232.99 2.56 25.63108.50 30.92% 23.62% 127 119 140 2 104.5 0.0894 95.15 11.00% 60 372267.51 2.56 29.43 124.58 30.92% 23.62% 146 137 151 3 99.4 0.0894 90.5511.00% 60 354 254.56 2.56 28.00 118.55 30.92% 23.62% 139 130 138 4 96.60.0894 87.99 11.00% 60 344 247.37 2.56 27.21 115.20 30.92% 23.62% 135127 135 5 103.4 0.0894 94.13 11.00% 60 368 264.63 2.56 29.11 123.2430.92% 23.62% 144 136 144 Sample L2 cut to size 12″ × 12″ L2 1 0.0 109.40.0894 99.64 11.00% 60 360 250.58 2.29 27.56 127.20 27.66% 21.67% 149140 147 2 107.6 0.0894 97.98 11.00% 60 354 246.40 2.29 27.10 125.0827.66% 21.67% 146 138 144 3 110.6 0.0894 100.75 11.00% 60 364 253.362.29 27.87 128.62 27.66% 21.67% 150 141 148 4 115.5 0.0894 105.18 11.00%60 380 264.50 2.29 29.09 134.27 27.66% 21.67% 157 148 154 5 115.5 0.0894105.18 11.00% 60 389 264.50 2.29 29.09 134.27 27.66% 21.67% 157 148 162Dry to Weight after 17% Drying Jute Fiber samples K2 & K3 cut to size12″ × 12″ K3 1 0.0 120.5 0.06 113.23 11.00% 60 418 297.54 2.47 32.73145.96 28.90% 22.42% 171 173 2 113.5 0.06 106.73 11.00% 60 394 280.462.47 30.85 137.58 28.90% 22.42% 161 157 3 117.0 0.06 109.98 11.00% 60406 289.00 2.47 31.79 141.77 28.90% 22.42% 166 163 4 115.9 0.06 108.9011.00% 60 402 286.15 2.47 31.48 140.38 28.90% 22.42% 164 159 5 111.80.06 105.11 11.00% 60 388 276.18 2.47 30.38 135.49 28.90% 22.42% 159 1556 119.3 0.06 112.15 11.00% 60 414 294.69 2.47 32.42 144.57 28.90% 22.42%169 169 7 112.4 0.06 105.65 11.00% 60 390 277.61 2.47 30.54 136.1928.90% 22.42% 159 140 8 117.0 0.06 109.98 11.00% 60 400 289.00 2.4731.79 141.77 28.90% 22.42% 166 153 9 110.1 0.06 103.48 11.00% 60 382271.91 2.47 29.91 133.39 28.90% 22.42% 156 155 10  108.9 0.06 102.4011.00% 60 378 269.07 2.47 29.60 131.99 28.90% 22.42% 154 145 11  123.30.06 115.94 11.00% 60 428 304.66 2.47 33.51 149.45 28.90% 22.42% 175 17012  113.5 0.06 106.73 11.00% 60 394 280.46 2.47 30.85 137.58 28.90%22.42% 161 161 13  114.7 0.06 107.82 11.00% 60 398 283.30 2.47 31.16138.98 28.90% 22.42% 163 161 14  121.0 0.06 113.78 11.00% 60 420 298.962.47 32.89 146.66 28.90% 22.42% 172 171 15  131.4 0.06 123.53 11.00% 60456 324.59 2.47 35.70 159.23 28.90% 22.42% 186 189 K2 1 0.0 123.1 0.06115.73 11.00% 60 426 302.88 2.46 33.32 149.05 28.79% 22.35% 174 175 2122.5 0.06 115.19 11.00% 60 424 301.46 2.46 33.16 148.35 28.79% 22.35%174 174 3 130.1 0.06 122.25 11.00% 60 450 319.94 2.46 35.19 157.4528.79% 22.35% 184 185 4 119.1 0.06 111.93 11.00% 60 412 292.92 2.4632.22 144.15 28.79% 22.35% 169 168 5 115.6 0.06 108.67 11.00% 60 400284.39 2.46 31.28 139.95 28.79% 22.35% 164 161 6 121.4 0.06 114.1011.00% 60 420 298.61 2.46 32.85 146.95 28.79% 22.35% 172 170 7 122.00.06 114.65 11.00% 60 422 300.03 2.46 33.00 147.65 28.79% 22.35% 173 1738 122.5 0.06 115.19 11.00% 60 424 301.46 2.46 33.16 148.35 28.79% 22.35%174 173 9 113.9 0.06 107.04 11.00% 60 394 280.13 2.46 30.81 137.8528.79% 22.35% 161 161 10  120.2 0.06 113.02 11.00% 60 416 295.77 2.4632.53 145.55 28.79% 22.35% 170 171 11  104.0 0.06 97.80 11.00% 60 360255.95 2.46 28.15 125.96 28.79% 22.35% 147 146 12  115.0 0.06 108.1311.00% 60 398 282.97 2.46 31.13 139.25 28.79% 22.35% 163 164 13  123.10.06 115.73 11.00% 60 426 302.88 2.46 33.32 149.05 28.79% 22.35% 174 17414  121.4 0.06 114.10 11.00% 60 420 298.61 2.46 32.85 146.95 28.79%22.35% 172 170 15  126.6 0.06 118.99 11.00% 60 438 311.41 2.46 34.26153.25 28.79% 22.35% 179 182 Acrodur dry Acrodur dry solid Resin solidResin 950 L Post weight rate weight rate Acrodur Mat weight Squeeze DryResin based on dry based on dry Base weight Nominal Dry Base SolidsRatio Soak Time after Wet Pickup % solution Solids Pickup Mat Dry baseweight Mat weight Weight after SAMPLE # GSM Weight (gr) Mositure (%)Weight (gr) to Water (%) (sec) squeeze (gr) Rate (gr) pick up rate Rate(gr) Weight (gr) (gr) (gr) Drying TEST # 01 (A) (90% Shoody + 10% Bico)A2 1134 1700 0.0894 1548.02 11.00% 60 6200 4500 264.71% 495 2043.0231.98% 24.23% 2200 A5 1161 1750 0.0894 1593.55 11.00% 60 6250 4500257.14% 495 2088.55 31.06% 23.70% 2300 A6 1117 1650 0.0894 1502.4911.00% 60 6100 4450 269.70% 489.5 1991.99 32.58% 24.57% 2200 A8 10691600 0.0894 1456.96 11.00% 60 6100 4500 281.25% 495 1951.96 33.97%25.36% 2100 A10 1140 1700 0.0894 1548.02 11.00% 60 6200 4500 264.71% 4952043.02 31.98% 24.23% 2250 TEST # 02 (B) (90% Shoody + 10% Bico) B3 11721750 0.0894 1593.55 7.00% 60 6300 4550 260.00% 318.5 1912.05 19.99%16.66% 2100 B4 1229 1800 0.0894 1639.08 7.00% 60 6450 4650 258.33% 325.51964.58 19.86% 16.57% 2200 B6 1203 1800 0.0894 1639.08 7.00% 60 64504650 258.33% 325.5 1964.58 19.86% 16.57% 2150 B7 1225 1850 0.08941684.61 7.00% 60 6600 4750 256.76% 332.5 2017.11 19.74% 16.48% 2250 B81184 1750 0.0894 1593.55 7.00% 60 6400 4650 265.71% 325.5 1919.05 20.43%16.96% 2150 TEST # 03 (C) (90% Shoody + 10% Bico) C2 1274 1850 0.08941684.61 5.00% 60 6550 4700 254.05% 235 1919.61 13.95% 12.24% 2150 C31251 1850 0.0894 1684.61 5.00% 60 6450 4600 248.65% 230 1914.61 13.65%12.01% 2100 C4 1274 1900 0.0894 1730.14 5.00% 60 6550 4650 244.74% 232.51962.64 13.44% 11.85% 2150 C5 1255 1850 0.0894 1684.61 5.00% 60 65004650 251.35% 232.5 1917.11 13.80% 12.13% 2100 C6 1263 1900 0.08941730.14 5.00% 60 6350 4450 234.21% 222.5 1952.64 12.86% 11.39% 2100 TEST# 04 (D) (90% Shoody + 10% Bico) D5 1046 1550 0.0894 1411.43 7.00% 605850 4300 2.77 301 1712.43 21.33% 17.58% 1900 D6 1013 1550 0.08941411.43 7.00% 60 5950 4400 2.84 308 1719.43 21.82% 17.91% 1850 D7 10091500 0.0894 1365.9 7.00% 60 5800 4300 2.87 301 1666.9 22.04% 18.06% 1850D8 1042 1550 0.0894 1411.43 7.00% 60 5900 4350 2.81 304.5 1715.93 21.57%17.75% 1900 D9 1002 1500 0.0894 1365.9 7.00% 60 5650 4150 2.77 290.51656.4 21.27% 17.54% 1800 TEST # 05 (E) (90% Shoody + 10% Bico) E1 9711450 0.0894 1320.37 11.00% 60 5900 4450 3.07 489.5 1809.87 37.07% 27.05%2000 E2 994 1450 0.0894 1320.37 11.00% 60 5650 4200 2.90 462 1782.3734.99% 25.92% 2000 E3 993 1450 0.0894 1320.37 11.00% 60 5750 4300 2.97473 1793.37 35.82% 26.37% 2000 E5 908 1350 0.0894 1229.31 11.00% 60 57004350 3.22 478.5 1707.81 38.92% 28.02% 1900 E6 921 1350 0.0894 1229.3111.00% 60 5750 4400 3.26 484 1713.31 39.37% 28.25% 1900 TEST # 06 (F)(45% Shoody + 25% PET + 20% Hemp + 10% Bico) F3 1028 1546 0.05 1468.711.00% 60 6450 4904 3.17 539.44 2008.14 36.73% 26.86% 2150 F4 1033 15540.05 1476.3 11.00% 60 6450 4896 3.15 538.56 2014.86 36.48% 26.73% 2150F7 993 1510 0.05 1434.5 11.00% 60 6200 4690 3.11 515.9 1950.4 35.96%26.45% 2100 F9 1025 1550 0.05 1472.5 11.00% 60 6250 4700 3.03 517 1989.535.11% 25.99% 2100 F10 990 1476 0.05 1402.2 11.00% 60 5850 4374 2.9634481.14 1883.34 34.31% 25.55% 2050 TEST # 07 (G) (45% Shoody + 25% PET +20% Hemp + 10% Bico) G3 1092 1642 0.05 1559.9 7.00% 60 6300 4658 2.84326.06 1885.96 20.90% 17.29% 2000 G4 1114 1676 0.05 1592.2 7.00% 60 61004424 2.64 309.68 1901.88 19.45% 16.28% 2050 G6 1166 1754 0.05 1666.311.00% 60 6650 4896 2.79 538.56 2204.86 32.32% 24.43% 2400 G8 1145 17220.05 1635.9 11.00% 60 6600 4878 2.83 536.58 2172.48 32.80% 24.70% 2350G9 1162 1748 0.05 1660.6 11.00% 60 6550 4802 2.75 528.22 2188.82 31.81%24.13% 2300 TEST # 08 (H) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)H2 1390 2090 0.05 1985.5 5.00% 60 6950 4860 2.33 243 2228.5 12.24%10.90% 2450 H4 1388 2088 0.05 1983.6 5.00% 60 7250 5162 2.47 258.12241.7 13.01% 11.51% 2450 H5 1400 2106 0.05 2000.7 5.00% 60 7050 49442.35 247.2 2247.9 12.36% 11.00% 2400 50% PP + 40% Shoddy + 10% Bico Test# 09 (I) Test # 09 (J) Sample # GSM weight (gr) Sample # GSM weight (gr)I-1 1247 1896 J-1 1444 2302 I-2 1150 1748 J-2 1438 2292 I-3 1171 1780J-3 1435 2288 I-4 1168 1776 J-4 1292 2060 I-5 1253 1904 J-5 1355 2160I-6 1154 1754 J-6 1413 2252 I-7 1167 1774 J-7 1395 2224 I-8 1238 1882J-8 1359 2166 I-9 1132 1720 J-9 1403 2236 I-10 1151 1749 J-10 1408 2244Dry Acrodur dry Acrodur dry Dry Resin Mat solid Resin solid Resin Weightcible Weight cible Base Nominal Base 950 L Acrodur Soak Mat weight PostSqueeze Solids Dry weight rate weight rate after drying = after drying =SAMPLE GSM weight Mositure Weight Solids Ratio to Time after squeeze WetPickup Rate % solution pick Pickup Weight based on dry based on dry 1.17× dry mat 1.10 × dry mat # Weight (gr) (%) (gr) Water (%) (sec) (gr)(gr) up rate Rate (gr) (gr) base weight (gr) Mat weight (gr) weight (gr)weight (gr) M1-1 1500 0.06 1410 6.00% 30 6000 4500 300.00% 270 168019.15% 16.07% 1965.6 1848 M1-2 1450 0.06 1363 6.00% 30 5950 4500 310.34%270 1633 19.81% 16.53% 1910.61 1796.3 M1-3 1350 0.06 1269 6.00% 30 59004550 337.04% 273 1542 21.51% 17.70% 1804.14 1696.2 M1-4 1450 0.06 13636.00% 30 5950 4500 310.34% 270 1633 19.81% 16.53% 1910.61 1596.3 M1-51350 0.06 1269 6.00% 30 5850 4500 333.33% 270 1539 21.28% 17.54% 1800.631692.9 M1-6 1700 0.06 1598 6.00% 30 6400 4700 276.47% 282 1880 17.65%15.00% 2199.6 2068 M1-7 1550 0.06 1457 6.00% 30 6150 4600 296.77% 2761733 18.94% 15.93% 2027.61 1906.3 M1-8 1700 0.06 1598 6.00% 30 6350 4650273.53% 279 1877 17.46% 14.86% 2196.09 2064.7 M1-9 1500 0.06 1410 6.00%30 6200 4700 313.33% 282 1692 20.00% 16.67% 1979.64 1861.2 M1-10 17000.06 1598 6.00% 30 6350 4650 273.53% 279 1877 17.46% 14.86% 2196.092064.7 Acrodur % Test # Recipe Target GSM 1 Jute FR 35% 12% 1000 Bico20% Shoddy 45% Acudur Test May 31, 2011 Acrodure Solution used: 3515 25%Resine 75% H2O Drying Process Convection Temp (C.) = 121 1A Dipping andsqueezing process sample Exit Airlay Conditions wet Pad Sol Acr (g)Resine H2O ID Composition Weight (g) gsm (g) W (g) % Pick-up W (g) % W(g) % 1-A 100% polyester 109 1214 256 147 135% 37 14% 110 43% 2-A 90%jute + 10Bico 83 921 280 197 237% 49 18% 148 53% 3-A 90% shoddy + 10%Bico 98 1086 248 150 153% 38 15% 113 45% 4-A* 63% shoddy + 20% Hollow +17% Bico 134 1486 339 205 153% 51 15% 154 45% 5-A** 62% shoddy + 20%Hollow + 18% Bico 133 1473 331 198 149% 50 15% 149 45% 6-A 90% cotton +10% Bico 69 767 204 135 196% 34 17% 101 50% *Rieter Tilsonburg **RieterOregon 2A Dipping and squeezing process sample Exit Airlay Conditionswet Pad Sol Acr (g) Resine H2O ID Composition Weight (g) gsm Dray Pad(g) W (g) % Pick-up W (g) % W (g) % 4-A* 63% shoddy + 20% Hollow + 17%Bico 134 1486 122.02 339 205 153% 51 15% 154 45% Test Date: May 31, 2011Drying process Dry Pad Resine H2O Drying H2Oevp % H2O (g) W (g) % W (g)% (min) (g) evp 1B 178 37 21% 32 18% 25 78 71% 160 49 31% 28 17% 29 12081% 157 38 24% 22 14% 17 91 81% 224 51 23% 39 17% 26 115 75% 224 50 22%42 19% 23 107 72% 125 34 27% 22 18% 10 79 78% 2B 224 51 23% 39 17% 26115 75% 3A Post 950 L Squeeze Dry Acrodur Wet Resin Mat Nominal SolidsRatio Soak Mat weight Pickup Solids Dry Base weight Mositure Dry Base toWater Time after Rate % solution Pickup Weight SAMPLE # GSM Weight (gr)(%) Weight (gr) (%) (sec) squeeze (gr) (gr) pick up rate Rate (gr) (gr)4-A* 1486 134 0.0894 122.02 25.0% 60 339 205 153.0% 51.25 173.3 4-A*1486 134 0.05 127.3 25.0% 60 339 205 153.0% 51.25 178.6 4-A* 1486 1340.13 116.58 25.0% 60 339 205 153.0% 51.25 167.8 4-A* 1486 134 0.135115.91 25.0% 60 339 205 153.0% 51.25 167.2 5-A** 1374 133 0.135 115.04525.0% 60 331 198 148.9% 49.5 164.5 3A 1086 98 0.135 84.77 25.0% 60 248150 153.1% 37.5 122.3 3A 1086 98 0.0895 89.229 25.0% 60 248 150 153.1%37.5 126.7 3A 1086 98 0.05 93.1 25.0% 60 248 150 153.1% 37.5 130.6 1-A1214 109 0 109 25.0% 60 265 156 143.1% 39 148 3B Weight Weight AcrodurAcrodur cible cible dry solid dry solid after after Resin Resin drying =drying = weight weight 1.17 × 1.10 × rate based rate based dry dry ondry on dry mat mat base Mat weight weight weight (gr) weight (gr) (gr)(gr) 42.00% 29.58% 202.7 191 40.26% 28.70% 208.9 196 43.96% 30.54% 196.4185 44.22% 30.66% 195.6 184 43.03% 30.08% 192.5 181 44.24% 30.67% 143.1134 42.03% 29.59% 148.3 139 40.28% 28.71% 152.8 144 35.78% 26.35% 173.2163 Acrodur Samples Jun. 22, 2010 1A TEST # 01 (A) Acrodur dry Acrodurdry solid Resin solid Resin Weight cible 950 L Post weight rate weightrate after drying = Acrodur Mat weight Squeeze Dry Resin based on drybased on dry 1.10 × dry SAMPLE GSM Base weight Nominal Dry Base SolidsRatio Soak Time after Wet Pickup % solution pick up Solids Pickup MatDry base weight Mat weight mat weight # Weight (gr) Mositure (%) Weight(gr) to Water (%) (sec) squeeze (gr) Rate (gr) rate Rate (gr) Weight(gr) (gr) (gr) (gr) A1 1082 1600 0.0894 1456.96 11.00% 60 6000 4400275.00% 484 1940.96 33.22% 24.94% 2135.056 A2 1134 1700 0.0894 1548.0211.00% 60 6200 4500 264.71% 495 2043.02 31.98% 24.23% 2247.322 A3 10961600 0.0894 1456.96 11.00% 60 6150 4550 284.38% 500.5 1957.46 34.35%25.57% 2158.206 A4 1088 650 0.0894 1502.49 11.00% 60 6150 4500 272.73%49% 997.49 32.95% 24.78% 2297.239 A5 1161 1750 0.0894 1593.55 11.00% 606250 4500 257.14% 495 2088.55 31.06% 23.70% 2297.405 A6 1117 1650 0.08941502.49 11.00% 60 6100 4450 269.70% 489.5 1991.99 32.58% 24.57% 2191.189A7 1096 1650 0.0894 1502.49 11.00% 60 6200 4550 275.76% 500.5 2002.9933.31% 24.99% 2203.289 A8 1069 1600 0.0894 1456.96 11.00% 60 6100 4500281.25% 495 1951.96 33.97% 25.36% 2147.156 A9 1115 1700 0.0894 1548.0211.00% 60 6250 4550 267.65% 500.5 2048.52 32.33% 24.43% 2253.372 A101140 1700 0.0894 1548.02 11.00% 60 6200 4500 264.71% 495 2043.02 31.98%24.23% 2247.322 SOLUTION to prepare 11% solid acrodur 3 × total solution91 liter solution acrodur 950 L (50% resine) = 20 liter water = 3 × 71liter 1B 2100 −35.056 −1.54% 8.46% 2200 −47.322 −1.98% 8.02% 2200 46.7942.04% 12.04% 2182 −16.239 −0.65% 9.35% 2300 2.595 0.11% 10.11% 22008.811 0.38% 10.38% 2200 −3.289 −0.14% 9.86% 2100 −47.156 −2.06% 7.94%2200 −53.372 −2.23% 7.77% 2250 2.678 0.11% 10.11% 2A TEST # 01 (A)Acrodur dry Acrodur dry solid Resin solid Resin Weight cible Weightcible 950 L Post weight rate weight rate after drying = after drying =Base Nominal Acrodur Mat weight Squeeze % solution Dry Resin based ondry based on dry 1.17 × dry 1.10 × dry SAMPLE GSM weight Mositure DryBase Solids Ratio Soak Time after Wet Pickup pick up Solids Pickup MatDry base weight Mat weight mat weight mat weight # Weight (gr) (%)Weight (gr) to Water (%) (sec) squeeze (gr) Rate (gr) rate Rate (gr)Weight (gr) (gr) (gr) (gr) (gr) A1 1082 1600 0.05 1520 11.00% 60 60004400 275.00% 484 2004 31.84% 24.15% 2344.68 2204.4 A2 1134 1700 0.051615 11.00% 60 6200 4500 264.71% 495 2110 30.65% 23.46% 2468.7 2321 A31096 1600 0.05 1520 11.00% 60 6150 4550 284.38% 500.5 2020.5 32.93%24.77% 2363.985 2222.55 A4 1088 1650 0.05 1567.5 11.00% 60 6150 4500272.73% 495 2062.5 31.58% 24.00% 2413.125 2268.75 A5 1161 1750 0.051662.5 11.00% 60 6250 4500 257.14% 495 2157.5 29.77% 22.94% 2524.2752373.25 A6 1117 1650 0.05 1567.5 11.00% 60 6100 4450 269.70% 489.5 205731.23% 23.80% 2406.69 2262.7 A7 1096 1650 0.05 1567.5 11.00% 60 62004550 275.76% 500.5 2068 31.93% 24.20% 2419.56 2274.8 A8 1069 1600 0.051520 11.00% 60 6100 4500 281.25% 495 2015 32.57% 24.57% 2357.55 2216.5A9 1115 1700 0.05 1615 11.00% 60 6250 4550 267.65% 500.5 2115.5 30.99%23.66% 2475.135 2827.05 A10 1140 1700 0.05 1615 11.00% 60 6200 4500264.71% 495 2110 30.65% 23.46% 2468.7 2821 Acrodur Solid base dry weight12.00 88 13.64% 13.00 87 14.94% 14.00 86 16.28% 15.00 85 17.65% 16.00 8419.05% 17.00 83 20.48% 18.00 82 21.95% 19.00 81 23.46% 20.00 80 25.00%21.00 79 26.58% 22.00 78 28.21% 23.00 77 29.87% 24.00 76 31.58% 25.00 7533.33% 26.00 74 35.14% 27.00 73 36.99% 28.00 72 38.89% 29.00 71 40.85%30.00 70 42.86% 31.00 69 44.93% 32.00 68 47.06% 2B 2100 −104.4 −4.45%5.55% 2104.2 2200 −121 −4.90% 5.10% 2200 −22.55 −0.95% 9.05% 2182 −86.75−3.59% 6.41% 2182 2300 −73.25 −2.90% 7.10% 2200 −62.7 −2.61% 7.39% 2200−74.8 −3.09% 6.91% 2100 −116.5 −4.94% 5.06% 2200 −127.05 −5.13% 4.87%2250 −71 −2.88% 7.12% 3A 33.00 67 49.25% 34.00 66 51.52% 35.00 65 53.85%A4 1088 1650 0.135 1427.25 11.00% 60 6150 4500 272.73% 495 1922.2534.68% 25.75% 2249.033 2114.475 A4 1088 1650 0.14 1419 11.00% 60 61504500 272.73% 495 1914 34.88% 25.86% 2239.38 2105.4 3B 2400 150.96756.71% 23.71% 2400 160.62 7.17% 24.17% Impregnation Acrodur November 2011Acrodur dry Acrodur dry % Dry Resin solid Resin solid Resin Weight cibleWeight cible Base Nominal Dry Base 950 L Acrodur Soak Mat weight PostSqueeze solution Solids Mat Dry weight rate weight rate after drying =after drying = SAMPLE GSM weight Mositure Weight Solids Ratio to Timeafter squeeze Wet Pickup Rate pick Pickup Weight based on dry based ondry 1.17 × dry mat 1.10 × dry mat # Weight (gr) (%) (gr) Water (%) (sec)(gr) (gr) up rate Rate (gr) (gr) base weight (gr) Mat weight (gr) weight(gr) weight (gr) M1-1 1500 0.06 1410 6.00% 30 6000 4500 300.00% 270 168019.15% 16.07% 1965.6

1848 M1-2 1450 0.06 1363 6.00% 30 5950 4500 310.34% 270 1633 19.81%16.53% 1910.61 1793.3 M1-3 1350 0.06 1269 6.00% 30 5900 4550 337.04% 2731542 21.51% 17.70% 1804.14 1696.2 M1-4 1450 0.06 1363 6.00% 30 5950 4500310.34% 270 1633 19.81% 16.53% 1910.61 1796.3 M1-5 1350 0.06 1269 6.00%30 5850 4500 333.33% 270 1539 21.28% 17.54% 1800.63 1692.9 M1-6 17000.06 1598 6.00% 30 6400 4700 276.47% 282 1880 17.65% 15.00% 2199.6

2068 M1-7 1550 0.06 1457 6.00% 30 6150 4600 296.77% 276 1733 18.94%15.93% 2027.61 1906.3 M1-8 1700 0.06 1598 6.00% 30 6350 4650 273.53% 2791877 17.46% 14.86% 2196.09 2064.7 M1-9 1500 0.06 1410 6.00% 30 6200 4700313.33% 282 1692 20.00% 16.67% 1979.64 1861.2 M1-10 1700 0.06 1598 6.00%30 6350 4650 273.53% 279 1877 17.46% 14.86% 2196.09 2064.7 Acrodur %Test # Recipe Target GSM 1 Jute FR 35% 12% 1000 Bico 20% Shoddy 45%Summary - Samples July 2011 Acrodur dry Acrodur dry solid Resin solidResin 950 L Post weight rate weight rate Acrodur Mat weight Squeeze DryResin based on dry based on dry Base weight Nominal Dry Base SolidsRatio Soak Time after Wet Pickup % solution Solids Pickup Mat Dry baseweight Mat weight Weight after SAMPLE # GSM Weight (gr) Mositure (%)Weight (gr) to Water (%) (sec) squeeze (gr) Rate (gr) pick up rate Rate(gr) Weight (gr) (gr) (gr) Drying TEST # 01 (A) (90% Shoody + 10% Bico)A2 1134 1700 0.0894 1548.02 11.00% 60 6200 4500 264.71% 495 2043.0231.98% 24.23% 2200 A5 1161 1750 0.0894 1593.55 11.00% 60 6250 4500257.14% 495 2088.55 31.06% 23.70% 2300 A6 1117 1650 0.0894 1502.4911.00% 60 6100 4450 269.70% 489.5 1991.99 32.58% 24.57% 2200 A8 10691600 0.0894 1456.96 11.00% 60 6100 4500 281.25% 495 1951.96 33.97%25.36% 2100 A10 1140 1700 0.0894 1548.02 11.00% 60 6200 4500 264.71% 4952043.02 31.98% 24.23% 2250 TEST # 02 (B) (90% Shoody + 10% Bico) B3 11721750 0.0894 1593.55 7.00% 60 6300 4550 260.00% 318.5 1912.05 19.99%16.66% 2100 B4 1229 1800 0.0894 1639.08 7.00% 60 6450 4650 258.33% 325.51964.58 19.86% 16.57% 2200 B6 1203 1800 0.0894 1639.08 7.00% 60 64504650 258.33% 325.5 1964.58 19.86% 16.57% 2150 B7 1225 1850 0.08941684.61 7.00% 60 6600 4750 256.76% 332.5 2017.11 19.74% 16.48% 2250 B81184 1750 0.0894 1593.55 7.00% 60 6400 4650 265.71% 325.5 1919.05 20.43%16.96% 2150 TEST # 03 (C) (90% Shoody + 10% Bico) C2 1274 1850 0.08941684.61 5.00% 60 6550 4700 254.05% 235 1919.61 13.95% 12.24% 2150 C31251 1850 0.0894 1684.61 5.00% 60 6450 4600 248.65% 230 1914.61 13.65%12.01% 2100 C4 1274 1900 0.0894 1730.14 5.00% 60 6550 4650 244.74% 232.51962.64 13.44% 11.85% 2150 C5 1255 1850 0.0894 1684.61 5.00% 60 65004650 251.35% 232.5 1917.11 13.80% 12.13% 2100 C6 1263 1900 0.08941730.14 5.00% 60 6350 4450 234.21% 222.5 1952.64 12.86% 11.39% 2100 TEST# 04 (D) (90% Shoody + 10% Bico) D5 1046 1550 0.0894 1411.43 7.00% 605850 4300 2.77 301 1712.43 21.33% 17.58% 1900 D6 1013 1550 0.08941411.43 7.00% 60 5950 4400 2.84 308 1719.43 21.82% 17.91% 1850 D7 10091500 0.0894 1365.9 7.00% 60 5800 4300 2.87 301 1666.9 22.04% 18.06% 1850D8 1042 1550 0.0894 1411.43 7.00% 60 5900 4350 2.81 304.5 1715.93 21.57%17.75% 1900 D9 1002 1500 0.0894 1365.9 7.00% 60 5650 4150 2.77 290.51656.4 21.27% 17.54% 1800 TEST # 05 (E) (90% Shoody + 10% Bico) E1 9711450 0.0894 1320.37 11.00% 60 5900 4450 3.07 489.5 1809.87 37.07% 27.05%2000 E2 994 1450 0.0894 1320.37 11.00% 60 5650 4200 2.90 462 1782.3734.99% 25.92% 2000 E3 993 1450 0.0894 1320.37 11.00% 60 5750 4300 2.97473 1793.37 35.82% 26.37% 2000 E5 908 1350 0.0894 1229.31 11.00% 60 57004350 3.22 478.5 1707.81 38.92% 28.02% 1900 E6 921 1350 0.0894 1229.3111.00% 60 5750 4400 3.26 484 1713.31 39.37% 28.25% 1900 TEST # 06 (F)(45% Shoody + 25% PET + 20% Hemp + 10% Bico) F3 1028 1546 0.05 1468.711.00% 60 6450 4904 3.17 539.44 2008.14 36.73% 26.86% 2150 F4 1033 15540.05 1476.3 11.00% 60 6450 4896 3.15 538.56 2014.86 36.48% 26.73% 2150F7 993 1510 0.05 1434.5 11.00% 60 6200 4690 3.11 515.9 1950.4 35.96%26.45% 2100 F9 1025 1550 0.05 1472.5 11.00% 60 6250 4700 3.03 517 1989.535.11% 25.99% 2100 F10 990 1476 0.05 1402.2 11.00% 60 5850 4374 2.9634481.14 1883.34 34.31% 25.55% 2050 TEST # 07 (G) (45% Shoody + 25% PET +20% Hemp + 10% Bico) G3 1092 1642 0.05 1559.9 7.00% 60 6300 4658 2.84326.06 1885.96 20.90% 17.29% 2000 G4 1114 1676 0.05 1592.2 7.00% 60 61004424 2.64 309.68 1901.88 19.45% 16.28% 2050 G6 1166 1754 0.05 1666.311.00% 60 6650 4896 2.79 538.56 2204.86 32.32% 24.43% 2400 G8 1145 17220.05 1635.9 11.00% 60 6600 4878 2.83 536.58 2172.48 32.80% 24.70% 2350G9 1162 1748 0.05 1660.6 11.00% 60 6550 4802 2.75 528.22 2188.82 31.81%24.13% 2300 TEST # 08 (H) (45% Shoody + 25% PET + 20% Hemp + 10% Bico)H2 1390 2090 0.05 1985.5 5.00% 60 6950 4860 2.33 243 2228.5 12.24%10.90% 2450 H4 1388 2088 0.05 1983.6 5.00% 60 7250 5162 2.47 258.12241.7 13.01% 11.51% 2450 H5 1400 2106 0.05 2000.7 5.00% 60 7050 49442.35 247.2 2247.9 12.36% 11.00% 2400 50% PP + 40% Shoddy + 10% Bico Test# 09 (I) Test # 09 (J) Sample # GSM weight (gr) Sample # GSM weight (gr)I-1 1247 1896 J-1 1444 2302 I-2 1150 1748 J-2 1438 2292 I-3 1171 1780J-3 1435 2288 I-4 1168 1776 J-4 1292 2060 I-5 1253 1904 J-5 1355 2160I-6 1154 1754 J-6 1413 2252 I-7 1167 1774 J-7 1395 2224 I-8 1238 1882J-8 1359 2166 I-9 1132 1720 J-9 1403 2236 I-10 1151 1749 J-10 1408 2244

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What is claimed is:
 1. A system for producing cotton shoddy and/ornatural fiber matrices comprising a modified dip and squeeze processsystem combined with a modified injection system configured toimpregnate a non-foam resin directly into a non-woven matrix while thenon-woven matrix remains substantially submerged in a resin containedwithin a resin tank.
 2. A method for producing cotton shoddy and/ornatural fiber matrices comprising a modified dip and squeeze processcombined with a modified injection process that impregnates a non-foamresin directly into a non-woven matrix while the non-woven matrixremains substantially submerged in a resin contained within a resintank.